2002 Subaru Legacy Problems

What owners report

Owners of this model year most often describe a gasoline smell in the cabin, often in cold weather, and hesitation, surging or stalling while driving. Rust in the rear suspension and sub-frame, brake failures or fade in cold temperatures, and head gasket or coolant leaks are also reported, with rust and leaks building up over time while stalls and surges are often described as sudden. Recorded mileage ranges from about 12,000 to over 200,000 miles.

1. 1
   Fuel system

   Gasoline smell in the cabin, often in cold weather

   • 12 complaints (22%)
   • median 100,000 mi at 11.8 yrs old (8 state mileage, few)
   • filed 2006–2023

   Owners describe a strong smell of raw gasoline in the cabin, often after a cold start or in cold weather, and sometimes when the heater or defroster is running. Some describe fuel hoses or lines that have cracked, come loose or leak onto the engine or the ground, and a fuel line that was replaced was still reported as leaking when cold. According to complaints, some dealers found cracked or broken fuel hoses, and the dealer and the manufacturer said the hose clamps needed tightening each time. Mileage is recorded for several of these complaints, ranging from roughly 30,000 to over 200,000 miles, and most describe the odor on cold starts or in cold weather.

   What to check: Ask whether the fuel hoses, lines and hose clamps have been inspected, especially after cold starts, and whether any hose work has been done. Check for a gasoline smell with the heater or defroster on, and look under the engine and along the drive for wet spots or fuel stains.

   2 excerpts from owner complaints in NHTSA records

   “Any time it is cold, around 32f or lower, whether the vehicle is running or not, there is a terrible fuel smell inside the cabin. I have actually witnessed fuel evaporating out my window. I can't imagine this is a safe condition and a short internet search revealed that this is a very common problem. I don't understand why Subaru doesn't have to pay to fix this glaring safety issue.”

   NHTSA complaint #10654508, filed 2014-11, 68,000 miles

   “Our 2002 Subaru Legacy wagon has an obnoxious smell of gas in the interior after starting in cold weather. We have a small 1-year old who is risking brain damage from these fumes and I have researched the issues with the problem that Subaru is not acknowledging as a recall but a hidden service bulletin. The possibility of an engine fire and the inhalation of gas fumes poses threats far beyond what typically should call for a service recall. …”

   NHTSA complaint #10181565, filed 2007-02, 51,500 miles
2. 2
   Engine

   Hesitation, surging and stalling while driving

   • 10 complaints (19%)
   • median 19,374 mi at 1.7 yrs old (3 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2002–2004

   Owners describe hesitation when accelerating, followed by a sudden surge, rough running and sometimes backfiring, with the check engine light sometimes lit. Other complaints describe engines that stall without warning at any speed, or that stalled and could not be restarted until the vehicle was towed, where a fuel pump was found to need replacement. Some owners also describe the throttle pedal dropping to the floor with the engine racing when changing gears, or the car surging ahead while parking, and say the dealer could not duplicate the problem. Where mileage is recorded it is low, from about 12,000 to about 21,000 miles, and most complaints in this group do not give mileage.

   Recall 04V128000

   What to check: Ask whether the dealer has checked stored engine codes, the fuel pump and the throttle system, and whether any engine computer reprogramming has been done. On a test drive, accelerate gently from a stop, including in first gear, and check for stalling, hesitation or surging.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2002 Legacy gt with manual 5-spd transmission. The vehicle frequently stalls or hesitates in first gear. I am an experienced driver of manual-transmission vehicles, and other drivers have confirmed that the car is easily stalled in first gear. I have heard other Subaru drivers complain about this defect, particularly on npr's car talk program. This issue poses a real safety hazard when accelerating into highway traffic.”

   NHTSA complaint #10030679, filed 2003-08

   “1) check engine light lit;2) hesitation at dangerous times, especially through turns, occasional backfiring;3) three times in shop for warranty work, replacing air/fuel ratio sensor and reprogramming ECM/ecu/PCM.”

   NHTSA complaint #10073078, filed 2004-05, 19,374 miles
3. 3
   Suspension

   Rear suspension and sub-frame corrosion

   • 5 complaints (9%)
   • median 165,200 mi at 16.2 yrs old (3 state mileage, few)
   • filed 2014–2023

   Owners describe rust in the rear suspension and sub-frame, in some cases holed through, on cars from colder, salted-road regions. Complaints describe the rear end dropping after a minor bump, a tire shredding, and metal fragments falling while driving at low speed. According to complaints, a corrosion recall was marked as resolved at a dealer, and some owners say they were never notified of the recall. Recorded mileage for some of these complaints ranges from about 150,000 to about 169,000 miles, and mileage is not given for the rest, so the rust is described on older, higher-mileage cars.

   Recall 03V1530001 related service bulletin

   What to check: Check the rear sub-frame, suspension mounts and shock areas for rust, holes or flaking, especially on vehicles from salted-road regions. Ask whether the corrosion recall (03V153000) and the bulletin on rear sub-frame paint have been checked against the vehicle's VIN.

   2 excerpts from owner complaints in NHTSA records

   “I own a 2002 Subaru Legacy in western new york, I recently was told there was an issue that was recalled back in 2004 but my car was never notified or addressed of the issue with corrosion. The recall ( NHTSA campaign number: 03v153000 ) I was driving on the high way when I hit a small bump and the back end of the Subaru dropped and the tire started to shred causing me to loose control of the car , thank good the car came to a rest in the median and no crash or fatalities occurred.”

   NHTSA complaint #10991935, filed 2017-05, 165,200 miles

   “To whom it may concern. I’ve purchased a second hand vehicle from New Jersey I live in California. It is 2002 Subaru outback H-6 3.0 with 52,000 miles. Upon delivery I took it to orange coast Subaru for general inspection when it was brought to my attention that there’s an open recall from 2004 stating excessive corrosion in the rear sub frame. It applies on vehicles in cold wet states where New Jersey is one of them. Service advisor assure me that all is fine and they marked it as resolved. …”

   NHTSA complaint #11516418, filed 2023-04
4. 4
   Brakes

   Brake failure or fade, some in cold weather

   • 5 complaints (9%)
   • median 47,273 mi at 4.3 yrs old (5 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2003–2010

   Owners describe brakes that fail or fade in freezing or colder weather, with some saying the brakes only worked after the vehicle warmed up for several minutes. Other complaints describe brakes that failed while slowing for a turn and hit another vehicle, and rotors that rusted to the point of failure and had to be replaced on all four wheels. According to complaints, the dealer could not duplicate some of these failures, while in a brake fade complaint the dealer found a faulty valve and brake line. Recorded mileage in this group ranges from about 43,000 to about 115,000 miles, and the cold-weather reports fall within that range.

   Recall 02V079000

   What to check: Ask whether the master cylinder, brake valve and lines have been inspected for cold-weather performance, and whether the cold-temperature brake recall (02V079000) has been checked against the vehicle's VIN. On a test drive, especially on a cold morning, check for a firm pedal and normal stopping, and inspect the rotors for rust.

   2 excerpts from owner complaints in NHTSA records

   “The contact stated while attempting to slow down and make a left turn, the brakes failed causing the vehicle to hit another vehicle. This occurred under normal braking and road conditions. The occupant was wearing a seatbelt when the accident occurred. The vehicle was taken to a body repair shop for repairs. After body repairs were made, the vehicle was taken to the dealership. The dealership inspected the vehicle, but was unable to duplicate the problem. …”

   NHTSA complaint #10148750, filed 2006-01, 50,000 miles

   “The contact owns a 2002 Subaru Legacy outback. When the temperature is below 32 degrees, the brakes fail if the master cylinder is not warmed. The contact must allow the vehicle to warm up approximately five minutes in order for the brakes to function. The manufacturer stated that the VIN was not included in NHTSA campaign id number 02v079000 (service brakes, hydraulic: foundation components: master cylinder) and advised the contact to take the vehicle to the dealer to be diagnosed. …”

   NHTSA complaint #10257718, filed 2009-02, 115,000 miles
5. 5
   Engine cooling

   Head gasket and coolant leaks

   • 5 complaints (9%)
   • median 79,250 mi at 5.6 yrs old (4 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2006–2010

   Owners describe coolant leaks that complaints link to the head gaskets, with dealers in some reports trying to seal the leak or replacing a head gasket. In some reports a stop-leak treatment did not hold and the leak became worse. According to complaints, coverage under a warranty extension or campaign for these repairs was denied in some cases, and in some cases the dealer or the manufacturer cited the vehicle's VIN range. Recorded mileage for these complaints ranges from about 40,000 to about 127,000 miles, and mileage is not recorded for every complaint in the group.

   What to check: Ask whether the cooling system has been pressure tested and whether the head gaskets and coolant reservoir have been checked for leaks or residue. Check the service history for stop-leak treatments and any warranty or campaign work, and ask whether the vehicle's VIN is covered by any extension.

   2 excerpts from owner complaints in NHTSA records

   “Car had been parked for 2 1/2 days. On cold start it made a horrible noise, check engine light came on and car died. I towed it to an auto repair shop. They said noise was internal motor noise. I authorized r&r of the oil pan and the found the #3 rod bearing spun. This vehicle has never been abused nor neglected and I have service records showing every service done on time. All oil changes were done every 3500 miles. Also.. At 92k miles my car developed a head gasket leak. …”

   NHTSA complaint #10330889, filed 2010-05, 126,955 miles

   “Started with a burning smell, when having my car inspected, I was advised that I head a small head gasket leak. (my car was recalled and had the stop leak put in it) obviously it didn't work. The leak is worse and I am scheduling an appointment, wondering where the money is going to come from to fix a problem Subaru was aware of , ie. The recall!”

   NHTSA complaint #10197408, filed 2007-07

Buying note. Anyone considering this model year may want to check for fuel odor after cold starts, rear sub-frame rust, brake performance in cold weather and any coolant leaks, and to ask whether the listed recalls were completed for the vehicle.

Summary written with AI from a sample of 48 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.